Multi-level hysteresis voltage controllers for voltage modulators and methods for control thereof

ABSTRACT

Systems and methods that facilitate multilevel hysteresis voltage control methods for cascaded multilevel voltage modulators having a plurality of power cells connected in series and has any positive integer number of output voltage levels to control any unipolar voltage on the load of the voltage modulator, and transfer electrical power from an electrical grid via AC/DC converters or directly from energy storage elements of the power cells to that load. A method of operational rotation of the power cells of a multilevel voltage modulator, which ensures an equal power sharing among the power cells and voltage balancing of the energy storage elements of the power cells of the modulator.

CROSS-REFERENCE TO RELATED APPLICATIONS

The subject application is a continuation of U.S. patent applicationSer. No. 17/409,295, filed Aug. 23, 2021, which is a continuation ofU.S. patent application Ser. No. 16/704,797, filed Dec. 5, 2019, nowU.S. Pat. No. 11,133,739, which is a continuation of PCT PatentApplication No. PCT/US18/38089, filed Jun. 18, 2018, which claimspriority to U.S. Provisional Patent Application No. 62/521,227, filed onJun. 16, 2017, all of which are incorporated by reference herein intheir entirety for all purposes.

TECHNICAL FIELD

The present disclosure relates to power electronic circuits, and moreparticularly to multi-level hysteresis voltage controllers for voltagemodulators and methods for control thereof.

BACKGROUND

Voltage modulators have been used widely for broadcast, medical,industrial and research applications. The most common voltage modulationtechniques include Pulsed Step Modulation, Coarse Step Modulation,Pulsed Width Modulation, and hybrid modifications thereof.

These common modulation techniques have several drawbacks. For instance,these common modulation techniques are linear methods that require aproportional-integral (PI) controller with an additional feedforwardloop in a control system to estimate a modulation index or duty cycle atevery step of discretization. In addition, low frequency pulsations ofoutput voltage usually occur in these common modulation techniques dueto unbalance of DC-link voltages, variation in parameters of passiveelements, and deviations of duty cycles of series connected modules.Lastly, there is a strong correlation between parameters of thePI-controller and load parameters in these common modulation techniques.Therefore, if load characteristics change rapidly and over a wide range,then the PI-controller is not capable of operating efficiently and fastenough to minimize a control error in transient periods.

Hysteresis is a phenomenon in which the response of a physical system toan external influence depends not only on the present magnitude of thatinfluence but also on the previous history of the system. Expressedmathematically, the response to the external influence is adoubled-valued function; one value applies when the influence isincreasing, while the other value applies when the influence isdecreasing.

Among existing control techniques, nonlinear hysteresis band voltagecontrol remains the simplest and fastest method. Beyond a fast responseof a voltage control loop, the nonlinear hysteresis band voltage controlmethod does not require any knowledge of variation of load parameters.However, the hysteresis voltage control technique for voltage modulatorsbecomes increasingly complicated with an increased number of power cellsconnected in series.

In view of the foregoing limitations, it is desirable to provide amultilevel hysteresis voltage controller (MHVC) for voltage modulatorshaving any number of series connected power cells while providing veryaccurate voltage regulation in a wide range of load parametersfluctuations.

SUMMARY

The embodiments of the present disclosure are directed to systems andmethods that facilitate simple and effective multilevel hysteresisvoltage control methods for cascaded multilevel voltage modulators. Inembodiments, a cascaded multilevel modulator comprises a plurality ofpower cells connected in series and has any positive integer number ofoutput voltage levels to quickly, effectively, and precisely control anyunipolar voltage on the load of the voltage modulator, and transferelectrical power from an electrical grid via AC/DC converters ordirectly from energy storage elements of the power cells to that load.The embodiments are also directed to a method of operational rotation ofthe power cells of a multilevel voltage modulator, which ensures anequal power sharing among the power cells and voltage balancing of theenergy storage elements of the power cells of the modulator.

The embodiments presented herein may advantageously be used in a varietyof applications in which voltage regulated modulators are employed.Examples of such applications may include, without limitation, powerelectronics circuits comprising: electrode biasing power supplies forTokamak and FRC plasma reactors; power supplies for neutral beaminjectors; magnetron modulators; klystron modulators; E-gun modulators;high power X-ray power supplies; mediumwave and longwave transmitters;and shortwave solid-state transmitters.

Other systems, methods, features and advantages of the exampleembodiments will be or will become apparent to one with skill in the artupon examination of the following figures and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The details of the example embodiments, including structure andoperation, may be gleaned in part by study of the accompanying figures,in which like reference numerals refer to like parts. The components inthe figures are not necessarily to scale, emphasis instead being placedupon illustrating the principles of the disclosure. Moreover, allillustrations are intended to convey concepts, where relative sizes,shapes and other detailed attributes may be illustrated schematicallyrather than literally or precisely.

FIG. 1 illustrates a schematic of a multi-level voltage modulatoraccording to embodiments of the present disclosure.

FIG. 2 illustrates an exemplary multi-level hysteresis voltagecontroller according to embodiments of the present disclosure.

FIG. 3 illustrates an exemplary voltage level estimator according toembodiments of the present disclosure.

FIGS. 4A, 4B, 4C, and 4D illustrate exemplary operation of an exemplaryvoltage level estimator according to embodiments of the presentdisclosure.

FIG. 5 illustrates an exemplary switching pattern generator according toembodiments of the present disclosure.

FIG. 6A illustrates an exemplary 1VDC rotation block according toembodiments of the present disclosure.

FIG. 6B illustrates an exemplary 2VDC rotation block according toembodiments of the present disclosure.

FIG. 6C illustrates an exemplary 3VDC rotation block according toembodiments of the present disclosure.

FIG. 6D illustrates an exemplary 4VDC rotation block according toembodiments of the present disclosure.

FIG. 6E illustrates an exemplary (N−1)VDC rotation block according toembodiments of the present disclosure.

FIGS. 7A, 7B, 7C, and 7D illustrate exemplary operation of an exemplaryswitching pattern generator according to embodiments of the presentdisclosure.

FIG. 8 illustrates exemplary switching and Levels signals for anexemplary seven (7) level voltage modulator according to embodiments ofthe present disclosure.

FIGS. 9A, 9B, and 9C illustrate simulation results of operation of theexemplary seven (7) level voltage modulator according to embodiments ofthe present disclosure.

FIGS. 10A, 10B, and 10C illustrate simulation results (zoomed traces) ofoperation of the exemplary seven (7) level voltage modulator accordingto embodiments of the present disclosure.

FIGS. 11A, 11B, and 11C illustrate exemplary experimental results ofoperation of an exemplary seven (7) level voltage modulator operatedwith active electrodes of diverts of an FRC reactor and according toembodiments of the present disclosure.

FIGS. 12A, 12B, and 12C illustrate exemplary experimental results ofoperation of an exemplary seven (7) level voltage modulator operatedwith active electrodes of diverts of an FRC reactor and according toembodiments of the present disclosure.

It should be noted that elements of similar structures or functions aregenerally represented by like reference numerals for illustrativepurpose throughout the figures. It should also be noted that the figuresare only intended to facilitate the description of the preferredembodiments.

DETAILED DESCRIPTION

The following embodiments are described in detail to enable thoseskilled in the art to make and use various embodiments of the presentdisclosure. It is understood that other embodiments would be evidentbased on the present disclosure, and that system, process, or changesmay be made without departing from the scope of the present embodiments.

In the following description, numerous specific details are given toprovide a thorough understanding of the present embodiments. However, itwill be apparent that the present embodiments may be practiced withoutthese specific details. In order to increase clarity, some well-knowncircuits, system configurations, and process steps may not be describedin detail.

The drawings showing embodiments of the present disclosure aresemi-diagrammatic and not to scale and, particularly, some of thedimensions are for the clarity of presentation and are shown exaggeratedin the drawing Figures.

The embodiments of the present disclosure are directed to systems andmethods that facilitate simple and effective multilevel hysteresisvoltage control methods for cascaded multilevel voltage modulators. Inembodiments, a cascaded multilevel modulator comprises a plurality ofpower cells connected in series and has any positive integer number ofoutput voltage levels to quickly, effectively, and precisely control anyunipolar voltage on the load of the voltage modulator, and transferelectrical power from an electrical grid via AC/DC converters ordirectly from energy storage elements of the power cells to that load.The embodiments are also directed to a method of operational rotation ofthe power cells of a multilevel voltage modulator, which ensures anequal power sharing among the power cells and voltage balancing of theenergy storage elements of the power cells of the modulator

In embodiments, an exemplary multilevel hysteresis voltage controller(MHVC) has a robust structure, which is free from the above-mentioneddrawbacks and does not have any additional regulation loops other than avoltage hysteresis loop. The output voltages of all power cells of thevoltage modulator are adjusted dynamically and in an automated manner byMHVC to maintain a minimum preset value of output voltage regulationerror, excluding an influence of variation of parameters of passivecomponents and the propagation delays of control signals on the outputvoltage oscillations. There are three major and interlinked tasks thatare performed by the MHVC: 1) maintenance of an voltage modulator'soutput voltage within the preset boundaries of regulation error; 2)identification of appropriate output voltage level at any moment oftime; and 3) rotation of the power cells.

Embodiments are directed to a fast MHVC design which can be realized onany FPGA or similar design component and can be operated at a high clockrate (tens of megahertz). The design comprises a hysteresis block, avoltage level estimator as described herein, and a switching patterngenerator as described herein.

FIG. 1 illustrates a schematic of a multi-level voltage modulator(voltage modulator) 100 according to embodiments of the presentdisclosure. A multi-level voltage modulator 100 is connected to athree-phase grid 101 on a lower voltage side and to a load 102 on highervoltage side, as well as a control system 105 having a MHVC. Functionsof the control system 105 may be implemented using either software orhardware processors including software routines, hardware components, orcombinations thereof.

The exemplary multi-level voltage modulator 100 comprises N seriesconnected cells 103A-103N, where each cell 103A-103N comprises asecondary winding of isolation transformer (V_(SECN)) 106A-106Nconnected to a three-phase diode bridge (DB_(N)) 107A-107N, a capacitivestorage element (C_(DCN)) 108A-108N on a DC side (DC-link) of the DB_(N)107A-107N, and a standard buck converter with an active bidirectionalswitch (S_(N)) 109A-109N (e.g., for high voltage modulators the S_(N)may include IGBT with freewheeling diode, while for lower voltagemodulators the S_(N) may include low voltage MOSFETs) and a diode(D_(N)) 110A-110N. It will be appreciated that N is a positive integer.Each cell 103A-103N may also be equipped with an optional LCR filter(L_(FN), C_(FN), R_(FN)) 11A-111N at its output and the voltagemodulator 100 may also be equipped with an optional CR filter (C_(FO),R_(FO)) 113 at its output. The DC-links of all of the power cells103A-103N are isolated from each other at the maximum load voltage levelby means of a three-phase multi-winding transformer (V_(SECN))106A-106N.

The voltage modulator 100 is assumed to be working in continuous mode,transferring the energy from the three-phase grid 101 to the load 102.It is also possible to operate the voltage modulator 100 completelydisconnected from the grid 101 for a certain period of time using theenergy accumulated in the storage elements (e.g., capacitors,supercapacitors, batteries) 108A-108N of the cells 103A-103N if thevoltage on the storage elements 108A-108N is not significantly reducedduring an operational time in order to maintain a desired output voltageon the load 102.

Each DC-link voltage of the voltage modulator's 100 power cells103A-103N of the voltage modulator 100 may be considered a DC voltagesource of a fixed magnitude (VC_(DCN)) which, in practice according tocertain embodiments, may be on the order of 12 to 1200 Volts. The totalvoltage across the series connected power cells 103A-103N (i.e., betweenterminals OUT+ 104A and OUT− 104B) is dependent upon the number of cellsthat have been turned on by closure of the associated switches S₁through S_(N) 109A-109N. For example, if all of the switches S₁ throughS_(N) 109A-109N are closed at the same time, then all of DC-link storageelements (e.g., capacitors) with voltage V_(DC1-N) are connectedtogether in series and added together (i.e., summed) to provide anoutput voltage equal to N times voltage V_(DC1-N). If each DC-linkvoltage source V_(DC1-N) has a value on the order of 800 Volts and N ison the order of 20, then the total output voltage of the voltagemodulator 100 may be on the order of 16,000 Volts.

If the switch S_(N) 109N in the power cell 103N is open (i.e., not inconducting mode) then this particular cell is “bypassed” and its outputvoltage is zero. Thus, the output voltage of the voltage modulator 100can be synthesized and modulated by the number of cells that are turnedON and OFF.

Referring to FIG. 1 to contrast, in the standard Pulse Step Modulation(PSM) technique, if there are N power cells in series in a voltagemodulator and each cell has a commutation period T(s), the switch S1 ofCELL 1 will be switched on at time t1, but the switch S2 of CELL 2 isturned on T/n (s) later than the first one, the third (S3) is turned on2T/n(s) later than the second (S2), and so on. This rotation method ofPSM ensures very low ripples at the output of the voltage modulator, astheir amplitude is reversely proportional to the frequency of ACcomponent f_(AC) of the output voltage of the voltage modulator. Allpower cells are switched at the same fixed switching frequency f_(SW),then f_(AC)=N*f_(SW).

Regulation of the output voltage using PSM is performed via linearregulation concepts (PI, feedforward or their combination) bycalculating the required number of power cells which have to be turnedon (Coarse Step Modulation), and/or regulation of duty cycle D (PulseWidth Modulation), which has to be the same for all power cells in casethe passive components (C_(DC), L_(F), R_(F), C_(F)) of all power cellsare absolutely identical, the stray capacitances are the same, as wellas the propagation delays of the control signals. However, in realityall passive components always have a slight variation of parameters, andthe propagation delays of control signals for power cells are not alwaysthe same. As a result, each power cell has to be switched on with adifferent required duty cycle D_(N), which has to be corrected in PSMbased control system by additional regulation loop using a DC-linkvoltage feedback signal. Moreover, additional adjustment of turn ontimes t1, t2 . . . tN can be necessary to eliminate the low frequencyoscillations of output voltage of the voltage modulator.

As discussed above, embodiments herein are directed to a multilevelhysteresis voltage controller (MHVC) having a robust structure, which isfree from the above-mentioned drawbacks and does not have any additionalregulation loops other than a single voltage hysteresis loop. The outputvoltages of all power cells 103A-103N of the voltage modulator 100 areadjusted dynamically and in an automated manner by the MHVC to maintaina minimum preset value of output voltage regulation error, excluding aninfluence of variation of parameters of passive components and thepropagation delays of control signals on the output voltageoscillations.

FIG. 2 illustrates an exemplary multi-level hysteresis voltagecontroller 200 of the control system 105 (see FIG. 1 ) according toembodiments of the present disclosure. An exemplary multi-levelhysteresis voltage controller 200 comprises a low pass filter(LP-filter) Filter1 201, a summation block Sum1 202, a hysteresis blockHyst1 203, a voltage level estimator 204, and a switching patterngenerator 205. A real feedback voltage signal V_(REAL) from a voltagesensor VS 112 (see FIG. 1 ) goes through a low pass filter Filter1 201to a negative input of the summation block Sum1 202, where it issubtracted from the reference voltage V_(REF) to generate a voltageerror signal ΔV, as their difference. The voltage error signal ΔV isinput into the hysteresis block Hyst1 203, which has the settings ofhigh boundary (HB) and low boundary (LB) thresholds. When ΔV reaches thehigh boundary (HB) of the hysteresis block Hyst1 203, the output valueof the hysteresis block Hyst1 203 is set to “1” and remains at thislevel until ΔV crosses its low boundary (LB) of the hysteresis blockHyst1 203. When ΔV crosses its low boundary (LB) of the hysteresis blockHyst1 203, the output value of the hysteresis block Hyst1 203 is set to“0” and the output is maintained at this level until ΔV reaches HBagain.

FIG. 3 illustrates an exemplary voltage level estimator 204 according toembodiments of the present disclosure. FIGS. 4A-4D illustrate exemplaryoperation of the exemplary voltage level estimator 204 according toembodiments of the present disclosure.

The voltage level estimator 204 operates in parallel with the hysteresisblock Hyst1 203. The voltage level estimator 204 receives the same HBand LB setting signals together with ΔV from the output of summationblock Sum1 202. The exemplary voltage level estimator 204 comprises aclock counting circuit formed by a clock generator Clock 210, a logicswitch Switch1 211 and a resettable counter Counter1 212. The exemplaryvoltage level estimator 204 further comprises a level decrement circuit220 comprising a logic element AND1 221, a rising edge detector RisingEdge 2 222 and a free running counter Counter2 223. The exemplaryvoltage level estimator 204 further comprises a level increment circuit230 having a logic element AND2 231, a rising edge detector Rising Edge3 232 and a free running counter Counter3 233. The exemplary voltagelevel estimator 204 further comprises an enable and reset circuit 240for Counter1 212, which comprises of a logic element XOR1 241, a risingedge detector Rising Edge 1 242 and a logic element OR1 243. Theexemplary voltage level estimator 204 further comprises a summationblock Sum1 250.

The block Counter1 212 is enabled when the clock signal goes through theupper input channel of Switch1 211 (in case of a True signal on itsmiddle input channel), and starts counting a number of clock cyclesgenerated by the Clock 210 in any of the following cases: If the outputof Comp1 213 is True, i.e. the signal ΔV is lower than the low boundaryhysteresis threshold LB (ΔV<LB). This case is illustrated in FIGS.4A-4D, where at the point C2 the signal ΔV becomes lower than LB and theCounter1 212 starts incrementing a count until ΔV returns to thehysteresis boundaries at the point D2 and the output signal of Comp1 213becomes False; If the output of Comp2 214 is True, i.e. the signal ΔV ishigher than the high boundary hysteresis threshold HB (ΔV>HB). This caseis illustrated in FIGS. 4A-4D, where at the point B1 the signal ΔVbecomes higher than HB and the Counter1 212 starts incrementing a countuntil ΔV returns to the hysteresis boundaries at the point C1 and theoutput signal of Comp2 214 becomes False.

The block Counter2 223 increments its output counting signal, which isapplied to the negative input of summation block Sum1 250, decrementinga number of Levels at the output of voltage level estimator 204, if bothof the following cases are true at the same time: If the output of Comp1213 is True, i.e. the signal ΔV is lower than the low boundaryhysteresis threshold LB (ΔV<LB); If the value of the output countingsignal of Counter1 212 is higher than a preset value of Time Constant(in cycles).

If both of the above mentioned conditions are satisfied, then the outputof AND1 221 becomes True and this fact is detected by the block RisingEdge 2 222, which generates a pulse of one clock cycle duration, and theblock Counter2 223 increments and holds its output count decrementing avalue at the output of Sum1 250 (the signal Levels at the output ofvoltage level estimator 204).

The block Counter3 233 increments its output counting signal, which isapplied to the positive input of summation block Sum1 250, incrementinga number of Levels at the output of voltage level estimator 204, if bothof the following cases are true at the same time: If the output of Comp2214 is True, i.e. the signal ΔV is higher than the high boundaryhysteresis threshold HB (ΔV>HB); If the value of the output countingsignal of Counter1 212 is higher than a preset value of Time Constant(in cycles).

If both of the above mentioned conditions are satisfied, then the outputof AND2 231 becomes True and this fact is detected by the block RisingEdge 3 232, which generates a pulse of one clock cycle duration, and theblock Counter3 233 increments and holds its output count incrementing avalue at the output of Sum1 250 (signal Levels at the output of voltagelevel estimator 204).

This case of incrementing of levels signal (increment of Counter3 233)is illustrated in FIGS. 4A-4D, where the point A2 satisfies the first oftwo presented above conditions and the point B2 corresponds to thesecond condition, when the output counting signal of Counter1 212 ishigher than a value of Time Constant preset at 500 clock cycles.

There are three conditions to be true to reset the Counter1 212 as canbe seen from FIG. 3 . If one of the output signals of the blocks RisingEdge 1 242, Rising Edge 2 222 and Rising Edge 3 232 is True, then theoutput of block OR1 243 is also True what actually resets the Counter1.

FIG. 5 illustrates an exemplary switching pattern generator 205according to embodiments of the present disclosure. The exemplaryswitching pattern generator enables a unique method of rotation of anoperation duty of the power cells 103A-103N of voltage modulator 100,which ensures an automatic power sharing among the power cells103A-103N, as well as an adjustment of duty cycle and phase shift ofcommutation of each power cell 103A-103N.

In embodiments, the exemplary switching pattern generator 205 comprisesa resettable Counter4 260 with a reset signal forming a circuit based onthe comparator block Comp4 262. The exemplary switching patterngenerator 205 further comprises a multiplexer Switch 1 263 with N inputsignals of constant values from 1 to N, where N is a number of powercells of voltage modulator 100. The exemplary switching patterngenerator 205 further comprises a multiplexer Switch 1 263 with N+1input signals, where each input signal is represented as an array ofswitching states and N−1 of them (1VDC Rotation, 2VDC Rotation . . .(N−1)VDC Rotation) are dynamic arrays and only two arrays OVDC and NVDCare static and have the constant values. The exemplary switching patterngenerator 205 receives the signal Levels from voltage level estimator204 and the signal State form the hysteresis block Hyst1 203. The outputsignals of the switching pattern generator 205 are N switching commandsto all N switching elements (said IGBTs) of voltage modulator 100.

FIGS. 7A-7D illustrate exemplary operation of the exemplary switchingpattern generator 205 according to embodiments of the presentdisclosure. The exemplary switching pattern generator for whichoperation is depicted in FIGS. 7A-7D is implemented in a seven-levelvoltage modulator consisting of seven power cells.

The Counter4 260 increments its output value at every rising edge of thesignal State (see FIGS. 7A-7D) up to value N, which sets the output ofComp4 261 to True and resets the Counter4 260. This output signal ofCounter4 260 chooses a constant value at the corresponding input of themultiplexer Switch 1 262 at every count and redirects it to the outputof the multiplexer Switch 1 262 forming the signal Cell_rot, which ispresented in FIGS. 7A-7D. Thus, the signal Cell_rot is changedrepetitively from N to 1 with a decrement of 1 at every rise edge of thesignal State.

The signal Levels coming from the voltage level estimator 204 passesthrough the summation block Sum2 263, where it is incremented by 1, andgoes to the control input of the multiplexer block Switch 2 264. Thismultiplexer commutates N+1 arrays of switching states corresponding tothe output voltage levels from 0VDC, when all switching signals areFalse (zero volts at the output of voltage modulator 100) to NVDC level,corresponding to the maximum output voltage of voltage modulator 100,when all switching signals are True. These two voltage levels, theminimum and the maximum output voltage levels, are created by the staticarrays (OVDC and NVDC, see FIG. 5 ) of switching states (signals) of thevoltage modulator 100 and no rotation of power cells is required.

The functional diagrams of N−1 blocks of dynamic arrays from 1VDCRotation to (N−1)DC rotation are presented in FIGS. 6A-6E.

FIG. 6A illustrates an exemplary 1VDC rotation block 265A according toembodiments of the present disclosure. FIG. 6B illustrates an exemplary2VDC rotation block 265B according to embodiments of the presentdisclosure. FIG. 6C illustrates an exemplary 3VDC rotation block 265Caccording to embodiments of the present disclosure. FIG. 6D illustratesan exemplary 4VDC rotation block 265D according to embodiments of thepresent disclosure. FIG. 6E illustrates an exemplary (N−1)VDC rotationblock 265E according to embodiments of the present disclosure.

Each of the blocks 265A-265E depicted in FIGS. 6A-6E comprises amultiplexer with a control input, which receives a signal Cell_rot fromthe block Switch 2 264, and having N commutated inputs. Each of theblocks 265A-265E depicted in FIGS. 6A-6E further comprises N staticarrays containing the specific switching states for correct rotation ofthe power cells 103A-103N of voltage modulator 100.

If the signal Levels takes the values 0 and 1 only, performing aregulation of the output voltage of the voltage modulator 100 betweenOVDC and 1VDC levels, then the 1VDC rotation block 265A is involved inoperation together with a static array OVDC. As can be seen from FIG.6A, each of N static arrays from 1VDC1 to 1VDCN of the block 1VDCrotation has only one high (True) switching state, which position inarray depends on a value of signal Cell_rot. For example if Cell_rot=1,then only first power cell 103A is operated providing a voltage of itsstorage element to the output of voltage modulator 100 via openedswitching element S₁ 109A (e.g., an IGBT) while all other power cells103B-103N are bypassed. A rotation of the power cells involved inproviding 1VDC level of output voltage is ensured by the signalCell_rot, which is changed repetitively from N to 1 with a decrement of1 at every rise edge of the signal State.

If the signal Levels takes the values 1 and 2 only, performing aregulation of the output voltage of the voltage modulator 100 between1VDC and 2VDC levels, then the 1VDC rotation block 265A and the 2VDCrotation block 265B are involved in operation together. As can be seenfrom FIG. 6B, each of N static arrays from 2VDC1 to 2VDCN of the 2VDCrotation block 265B has two high (True) switching states, whichpositions in array depend on a value of signal Cell_rot. For example ifLevels=2 and Cell_rot=1, then the first and the second power cells 103Aand 103B are operated providing a sum of the voltages of their storageelements to the output of voltage of the voltage modulator 100 viaopened switching elements S₁ and S₂ (109A and 109B) while all otherpower cells 103C-103N are bypassed. When the signal Levels changes to 1at every rising edge of the signal State, then only one power cellremains connected to the output and its number will be decremented by 1,because the signal Cell_rot is changed also with a rising edge of thesignal State. In this case a rotation of the power cells involved inproviding 1VDC and 2VDC levels of output voltage is ensured not only bythe signal Cell_rot, which is changed repetitively from N to 1 with adecrement of 1 at every rise edge of the signal State, but by thedistribution of the high (said True) switching states in the dynamicarrays of both the 1VDC and 2VDC rotation blocks 265A and 265B.

FIG. 8 illustrates exemplary switching signals for an exemplary seven(7) level voltage modulator according to embodiments of the presentdisclosure. FIG. 8 provides an example of the operation of the switchingpattern generator 205 for a case of a seven-level voltage modulatorcomprising seven power cells connected in series. As can be seen fromFIG. 8 , the Levels signal is changed first from 5 to 6 when the voltagemodulator 100 provides an output voltage between 5VDC and 6VDC levels,and then the Levels signals is switched between 6 and 7, when thevoltage modulator 100 regulates its output voltage between 6VDC and 7VDClevels. In both cases the switching signals S₁-S₇ (109A-109G) areshifted from each other ensuring a rotation of the power cells with anequal distribution of consumed power and providing an output frequencyof the output voltage to be seven times higher than the switchingfrequency of each individual power cell.

FIGS. 9A-9C illustrates simulation results of operation of the exemplaryseven (7) level voltage modulator according to embodiments of thepresent disclosure. FIG. 10 illustrates simulation results (zoomedtraces) of operation of the exemplary seven (7) level voltage modulatoraccording to embodiments of the present disclosure. The seven-levelvoltage modulator comprises seven power cells connected in series. Thereference output voltage V_(REF) is a sinusoidal waveform of 100 Hz withamplitude of 3 kV and DC-offset of 3.5 kV, thus a maximum output voltageis 6.5 kV and the minimum value is 0.5 kV (FIGS. 9A-9C). The proposedmulti-level hysteresis voltage controller operates in such a way tomaintain a regulation error ΔV in boundaries of preset values of HB andLB (30V and −30V respectively, see FIGS. 9A-9C and FIGS. 10A-10C). Anovershoot of ΔV in the level transition regions depends on the TimeConstant value and can be reduced further to the certain level byadjusting a value of Time Constant. The signal Levels presented in FIGS.9A-9C and FIGS. 10A-10C is increasing and decreasing following thereference voltage dynamic. The real output voltage V_(REAL) ismaintained around V_(REF) with a regulation error ΔV.

FIGS. 11A-11C and FIGS. 12A-12C show the experimental results of asingle-phase seven (7) level modulator comprising seven (7) cellsconnected in series with capacitive storage element on DC-link side asdepicted in FIG. 1 . The seven (7) level modulator is operated withactive electrodes installed in the diverters of the colliding beam FRCbased reactor. The active electrodes are in touch with the plasma andthe PSU provides the current of up to 5 kA to the plasma with an outputvoltage of up to 5 kV. The plasma parameters during a plasma dischargesignificantly and rapidly change and thus the required bias voltage hasto be regulated and stabilized at the desired reference value.

The reference voltage V_(REF) and real output voltage of the PSU V_(OUT)are shown as functions of time in FIG. 11B. As can be seen, V_(OUT) isregulated and stabilized around V_(REF) with a voltage control errorsignal presented in FIG. 11A while not exceeding a preset value of+/−100 A. The required number of levels of the output voltage calculatedby the Voltage Level Estimator block (204, see FIG. 2 ) is shown in FIG.11B. As the capacitor banks in the DC-links of power cells aredischarging it requires more levels of output voltage to be set up tomaintain a constant output voltage of 3.5 kV and the proposedmethodology calculates it accordingly. At the end of the pulse allcapacitor banks are discharged to the voltage, at which a setting of all8 levels is not enough regulate V_(OUT), which causes an increase ofoutput voltage error signal.

FIG. 12 shows the experimental results of operation of the same ActiveElectrode PSU with a triangle reference voltage V_(REF), demonstrating ahigh dynamic capability of proposed voltage hysteresis controller toregulate and stabilize a voltage with a fast changing dV/dt value.

Embodiments of the present disclosure are directed to a multi-levelcascaded voltage modulator connectable to a load. In embodiments, themulti-level cascaded voltage modulator comprises a plurality of powercells connected in series, wherein each cell of the plurality of cellscomprises a of bidirectional switch and a storage element, and a controlsystem coupled to the plurality of cells and having a multi-levelhysteresis voltage controller. In embodiments, the control system isconfigured to cause the plurality of cells to output N levels of voltageon the load, wherein N is a positive integer corresponding to the numberof power cells of the plurality of power cells.

In embodiments, each cell of the plurality of cells includes a secondarywinding isolation transformer, a three-phase diode bridge coupled to thetransformer and the storage element, and a diode.

In embodiments, the bidirectional switch is one of an IGBT or a MOSFET.

In embodiments, each cell of the plurality of cells further comprises anLCR filter at its output.

In embodiments, the modulator further comprises a CR filter at theoutput of the plurality of cells.

In embodiments, the control system is further configured to cause thetransfer of electrical power from the energy storage elements of thepower cells to the load.

In embodiments, the control system is further configured to balancevoltages on the storage elements.

In embodiments, the storage element is a capacitor.

In embodiments, the control system including one or more processorscoupled to a non-transitory memory comprising a plurality ofinstructions that when executed causes the one or more processors tocontrol a level of voltage on the load.

In embodiments, the plurality of instructions when executed causes theone or more processors to control an output voltage level of themodulator as a function of the level of voltage on the load, a referencevoltage and a voltage error equal to the difference between the level ofvoltage on the load and the reference voltage.

In embodiments, the plurality of instructions when executed causes theone or more processors to subtract from a reference voltage signalV_(REF) a real feedback voltage signal V_(REAL) received from a voltagesensor, produce, by a voltage level estimator, an estimated voltagelevel signal, Levels, using a high boundary (HB) threshold of ahysteresis block, a low boundary (LB) threshold of the hysteresis block,and the voltage difference signal ΔV, and generate, by a switchingpattern generator, a plurality of switching signals based on theestimated voltage level, Levels, and a state of the hysteresis block.

In embodiments, to subtract from a reference voltage signal V_(REF) areal feedback voltage signal V_(REAL), the plurality of instructionswhen executed causes the one or more processors to feed the realfeedback voltage signal V_(REAL) to a low-pass filter input, feed alow-pass filter output signal to a negative input of a first summationblock, feed the reference voltage signal V_(REF) to a positive input ofthe first summation block, and produce a voltage difference signal ΔV atan output of the first summation block.

In embodiments, when ΔV reaches the high boundary (HB) threshold of thehysteresis block, the plurality of instructions when executed causes theone or more processors to set the state of the hysteresis block to “1.”

In embodiments, when ΔV reaches the low boundary (LB) threshold of thehysteresis block, the plurality of instructions when executed causes theone or more processors to set the state of the hysteresis block to “0.”

In embodiments, to produce the estimated voltage level Levels, theplurality of instructions when executed causes the one or moreprocessors to apply a clock signal to a clock generator, count, by aresettable counter, a number of clock signals generated by the clockgenerator when one or more of the following conditions is true: ΔV islower than the low boundary (LB) threshold of the hysteresis block; orΔV is higher than the high boundary (HB) threshold of the hysteresisblock.

In embodiments, the plurality of instructions when executed causes theone or more processors further to, increment, by a free running counter,a free running counter output signal, apply the free running counteroutput signal to a second summation block, and decrement a number ofLevels at an output of the voltage level estimator when both of thefollowing cases are true at the same time: the signal ΔV is lower thanthe low boundary hysteresis threshold LB; and the value of an outputcounting signal of the resettable counter is higher than a preset valueof a time constant.

In embodiments, when both the signal ΔV is lower than the low boundaryhysteresis threshold LB and the value of the output counting signal ofthe resettable counter is higher than the preset value of a timeconstant, the plurality of instructions when executed causes the one ormore processors to set the output of a logic element of a leveldecrement circuit to True, detect the output of the logic element with arising edge detector, and increment the free running counter, andthereby decrement an output level at a summation block.

In embodiments, the multi-level hysteresis voltage controller comprisesa low pass filter having a low-pass filter input and a low-pass filteroutput, a first summation block having a positive input and a negativeinput, a hysteresis block having a high boundary (HB) threshold and alow boundary (LB) threshold, a voltage level estimator having aplurality of voltage level estimator inputs and a voltage level outputsignal Levels, and a switching pattern generator having a plurality ofswitching pattern generator inputs and a plurality of switching patterngenerator outputs.

In embodiments, the switching pattern generator comprises a comparatorblock, a resettable counter, a first multiplexer having a firstplurality of input signals, and a second multiplexer having a secondplurality of input signals.

In embodiments, each input signal of the second plurality of inputsignals represents an array of switching states each corresponding to aone of plurality of output levels for a voltage modulator.

In embodiments, the plurality of output levels ranges from OVDC when allswitching signals are false to a maximum output voltage when allswitching signals are true.

In embodiments, the voltage level estimator comprises, a clock countingcircuit, a level decrement circuit, an enable and reset circuit for theresettable counter, and a second summation block.

In embodiments, the clock counting circuit comprises a clock generator,a logic switch, and a resettable counter.

In embodiments, the level decrement circuit comprises a first logicelement, a rising edge detector, and a free running counter.

In embodiments, the enable and reset circuit comprises a second logicelement, a rising edge detector and a third logic element.

In embodiments, the first logic element is an AND gate, the second logicelement is an XOR gate, and the third logic element is an OR gate.

In embodiments, when ΔV reaches the high boundary (HB) threshold of thehysteresis block, the state of the hysteresis block is set to “1.”

In embodiments, when ΔV reaches the low boundary (LB) threshold of thehysteresis block, the state of the hysteresis block is set to “0.”

In embodiments, the load is in a power electronic circuit in one or moreof an electrode biasing power supply for a Tokamak plasma reactor, anelectrode biasing power supply for a FRC plasma reactor, a power supplyfor a neutral beam injector, a magnetron modulator, a klystronmodulator, an E-gun modulator, a high power X-ray power supply, amediumwave transmitter, a longwave transmitter, and a shortwavesolid-state transmitter.

Embodiments of the present disclosure are directed to a multi-levelhysteresis voltage controller connectable to a load. In embodiments, themulti-level hysteresis voltage controller (MHVC) comprises a low passfilter having a low-pass filter input and a low-pass filter output, afirst summation block having a positive input and a negative input, ahysteresis block having a high boundary (HB) threshold and a lowboundary (LB) threshold, a voltage level estimator having a plurality ofvoltage level estimator inputs and a voltage level output signal Levels;and a switching pattern generator having a plurality of switchingpattern generator inputs and a plurality of switching pattern generatoroutputs.

In embodiments, the switching pattern generator comprises a comparatorblock, a resettable counter, a first multiplexer having a firstplurality of input signals, and a second multiplexer having a secondplurality of input signals.

In embodiments, each input signal of the second plurality of inputsignals represents an array of switching states each corresponding to aone of plurality of output levels for a voltage modulator.

In embodiments, the plurality of output levels ranges from OVDC when allswitching signals are false to a maximum output voltage when allswitching signals are true.

In embodiments, the voltage level estimator comprises a clock countingcircuit, a level decrement circuit comprising, an enable and resetcircuit for the resettable counter, and a second summation block.

In embodiments, the clock counting circuit comprises a clock generator,a logic switch, and a resettable counter.

In embodiments, the level decrement circuit comprises a first logicelement, a rising edge detector, and a free running counter.

In embodiments, the enable and reset circuit comprises a second logicelement, a rising edge detector and a third logic element.

In embodiments, the first logic element is an AND gate, the logic secondelement is an XOR gate, and the third logic element is an OR gate.

In embodiments, when ΔV reaches the high boundary (HB) threshold of thehysteresis block, the state of the hysteresis block is set to “1.”

In embodiments, when ΔV reaches the low boundary (LB) threshold of thehysteresis block, the state of the hysteresis block is set to “0.”

In embodiments, the load is in a power electronic circuit in one or moreof an electrode biasing power supply for a Tokamak plasma reactor, anelectrode biasing power supply for a FRC plasma reactor, a power supplyfor a neutral beam injector, a magnetron modulator, a klystronmodulator, an E-gun modulator, a high power X-ray power supply, amediumwave transmitter, a longwave transmitter, and a shortwavesolid-state transmitter.

Embodiments of the present disclosure are directed to a method ofcontrolling a voltage supplied to a load using a multi-level hysteresisvoltage controller. In embodiments, the method comprises receiving areal feedback voltage signal V_(REAL) from a voltage sensor. Inembodiments, the method further comprises subtracting the real feedbackvoltage signal V_(REAL) from a reference voltage signal V_(REF) by:feeding the real feedback voltage signal V_(REAL) to a low-pass filterinput, feeding a low-pass filter output signal to a negative input of afirst summation block, feeding the reference voltage signal V_(REF) to apositive input of the summation block, and producing a voltagedifference signal ΔV at an output of the first summation block.

In embodiments, the method further comprises producing, by a voltagelevel estimator, an estimated voltage level signal, Levels, using a highboundary (HB) threshold of a hysteresis block, a low boundary (LB)threshold of the hysteresis block, and the voltage difference signal ΔV.In embodiments, the method further comprises generating, by a switchingpattern generator, a plurality of switching signals based on theestimated voltage level, Levels, and a state of the hysteresis block.

In embodiments, when ΔV reaches the high boundary (HB) threshold of thehysteresis block, the state of the hysteresis block is set to “1.”

In embodiments, when ΔV reaches the low boundary (LB) threshold of thehysteresis block, the state of the hysteresis block is set to “0.”

In embodiments, the voltage level estimator produces the estimatedvoltage level Levels by: applying a clock signal to a clock generator;counting, by a resettable counter, a number of clock signals generatedby the clock generator when one or more of the following conditions istrue: ΔV is lower than the low boundary (LB) threshold of the hysteresisblock, or ΔV is higher than the high boundary (HB) threshold of thehysteresis block; incrementing, by a free running counter, a freerunning counter output signal; applying the free running counter outputsignal to a summation block; and decrementing a number of Levels at anoutput of the voltage level estimator when both of the following casesare true at the same time: the signal ΔV is lower than the low boundaryhysteresis threshold LB, and the value of an output counting signal ofthe resettable counter is higher than a preset value of a time constant.

In embodiments, when both the signal ΔV is lower than the low boundaryhysteresis threshold LB and the value of the output counting signal ofthe resettable counter is higher than the preset value of a timeconstant, a first logic element output of a level decrement circuitbecomes True; a rising edge detector detects the first logic elementoutput; and the free running counter is incremented, therebydecrementing an output level at a summation block.

The processors of the control systems and controllers of the presentdisclosure may be configured to perform the computations and analysesdescribed in the present disclosure and may include or becommunicatively coupled to one or more memories including non-transitorycomputer readable medium. It may include a processor-based ormicroprocessor-based system including systems using microcontrollers,reduced instruction set computers (RISC), application specificintegrated circuits (ASICs), logic circuits, and any other circuit orprocessor capable of executing the functions described herein. The aboveexamples are exemplary only, and are thus not intended to limit in anyway the definition and/or meaning of the term “processor” or “computer.”

Functions of the processor may be implemented using either softwareroutines, hardware components, or combinations thereof. The hardwarecomponents may be implemented using a variety of technologies,including, for example, integrated circuits or discrete electroniccomponents. The processor unit typically includes a readable/writeablememory storage device and typically also includes the hardware and/orsoftware to write to and/or read the memory storage device.

The processors may include a computing device, an input device, adisplay unit and an interface, for example, for accessing the Internet.The computer or processor may include a microprocessor. Themicroprocessor may be connected to a communication bus. The computer orprocessor may also include a memory. The memory may include RandomAccess Memory (RAM) and Read Only Memory (ROM). The computer orprocessor may also include a storage device, which may be a hard diskdrive or a removable storage drive such as, e.g., an optical disk driveand the like. The storage device may also be other similar means forloading computer programs or other instructions into the computer orprocessor.

The processor executes a set of instructions that are stored in one ormore storage elements, in order to process input data. The storageelements may also store data or other information as desired or needed.The storage element may be in the form of an information source or aphysical memory element within a processing machine.

The set of instructions may include various commands that instruct theprocessors as a processing machine to perform specific operations suchas the methods and processes of the various embodiments of the subjectmatter described herein. The set of instructions may be in the form of asoftware program. The software may be in various forms such as systemsoftware or application software. Further, the software may be in theform of a collection of separate programs or modules, a program modulewithin a larger program or a portion of a program module. The softwarealso may include modular programming in the form of object-orientedprogramming. The processing of input data by the processing machine maybe in response to user commands, or in response to results of previousprocessing, or in response to a request made by another processingmachine.

As used herein, the terms “software” and “firmware” may beinterchangeable, and include any computer program stored in memory forexecution by a computer, including RAM memory, ROM memory, EEPROMmemory, and non-volatile RAM (NVRAM) memory. The above memory types areexemplary only, and are thus not limiting as to the types of memoryusable for storage of a computer program.

All features, elements, components, functions, and steps described withrespect to any embodiment provided herein are intended to be freelycombinable and substitutable with those from any other embodiment. If acertain feature, element, component, function, or step is described withrespect to only one embodiment, then it should be understood that thatfeature, element, component, function, or step can be used with everyother embodiment described herein unless explicitly stated otherwise.This paragraph therefore serves as antecedent basis and written supportfor the introduction of claims, at any time, that combine features,elements, components, functions, and steps from different embodiments,or that substitute features, elements, components, functions, and stepsfrom one embodiment with those of another, even if the followingdescription does not explicitly state, in a particular instance, thatsuch combinations or substitutions are possible. Express recitation ofevery possible combination and substitution is overly burdensome,especially given that the permissibility of each and every suchcombination and substitution will be readily recognized by those ofordinary skill in the art upon reading this description.

In many instances entities are described herein as being coupled toother entities. It should be understood that the terms “coupled” and“connected” or any of their forms are used interchangeably herein and,in both cases, are generic to the direct coupling of two entitieswithout any non-negligible e.g., parasitic intervening entities and theindirect coupling of two entities with one or more non-negligibleintervening entities. Where entities are shown as being directly coupledtogether, or described as coupled together without description of anyintervening entity, it should be understood that those entities can beindirectly coupled together as well unless the context clearly dictatesotherwise.

While the embodiments are susceptible to various modifications andalternative forms, specific examples thereof have been shown in thedrawings and are herein described in detail. It should be understood,however, that these embodiments are not to be limited to the particularform disclosed, but to the contrary, these embodiments are to cover allmodifications, equivalents, and alternatives falling within the spiritof the disclosure. Furthermore, any features, functions, steps, orelements of the embodiments may be recited in or added to the claims, aswell as negative limitations that define the inventive scope of theclaims by features, functions, steps, or elements that are not withinthat scope.

What is claimed is:
 1. A multi-level cascaded voltage modulator,comprising: a plurality of cells connected in series, wherein each cellcomprises a switch and a storage element; a cell rotation valuegenerator that receives, as input, a signal based on an output of avoltage hysteresis block and generates, in response to the signal, acell rotation value; a switching signals generator that receives, asinput, an input signal based on a voltage level signal and the cellrotation value, and in response, generates a set of switching signals,wherein each switching signal is respectively generated for a respectivecell of the plurality of cells; and wherein the switching signals arerespectively applied to the respective switches of the respective cells.2. The multi-level cascade voltage modulator of claim 1, wherein: theplurality of cells comprise N cells; the switching signals generator cangenerate a plurality of different sets of switching signals, and eachset of switching signals generated by the switching signals generator,when applied to the respective switches of the respective cells, causefrom 0 to N of the cells to each output a positive DC voltage VDC; andthe cell rotation value generated by the cell rotation value generator,when applied to the switching signals generator, specifies respectivesets of switching signals for 1 to N−1 cells to each output the voltageVDC.
 3. The multi-level cascaded voltage modulator of claim 2, whereinthe cell rotation value generator further comprises: a first multiplexerswitch that receives, as input, an output value from 1 to N andgenerates, in response to the output value, the cell rotation value. 4.The multi-level cascaded voltage modulator of claim 3, wherein the cellrotation value generator further comprises: a counter, wherein thecounter generates the output value from 1 to N based on the signal thatis based on the output of the voltage hysteresis block and a resetsignal.
 5. The multi-level cascaded voltage modulator of claim 4,wherein the cell rotation value generator further comprises: acomparator, wherein the comparator compares an N value and the outputvalue from 1 to N and, in response, generates the reset signal.
 6. Themulti-level cascaded voltage modulator of claim 2, wherein the switchingsignals generator further comprises: a second multiplexer switch thatreceives, as input, respective rotation block outputs of a plurality ofrotation block generators and an output signal of a summation block, andin response, generates the set of switching signals.
 7. The multi-levelcascaded voltage modulator of claim 6, wherein the switching signalsgenerator further comprises: the summation block, wherein the summationblocks receives the voltage level signal and a static value, and inresponse, generates the output signal of the summation block; and theplurality of rotation blocks, wherein each rotation block generates arespective rotation block output.
 8. The multi-level cascaded voltagemodulator of claim 7, wherein each rotation block of the plurality ofrotation blocks receives the cell rotation value as input and inresponse, generates a respective set of switching signals based on thecell rotation value.
 9. The multi-level cascaded voltage modulator ofclaim 8, wherein each cell rotation value specifies a number of activecells and a position of the active cells, wherein each active celloutputs the voltage VDC.
 10. A method performed in a voltage modulator,comprising: receiving a hysteresis state signal that is generated basedon a voltage sensed on a load; generating, in response to the hysteresisstate signal, a cell rotation value; receiving an input signal based ona voltage level signal; generating, in response to the voltage levelsignal and the cell rotation value, a set of switching signals, whereineach switching signal is respectively generated for a respective cell ofa plurality of cells connected in series, wherein each cell comprises aswitch and a storage element; and wherein the switching signals arerespectively applied to the respective switches of the respective cellsto generate an output voltage for the load.
 11. The method of claim 10,wherein: the plurality of cells comprise N cells; generating, inresponse to the voltage level signal and the cell rotation value, a setof switching signals comprises generating one of a plurality sets ofswitching signals, wherein each set of set of switching signals, whenapplied to the respective switches of the respective cells, cause from 0to N of the cells to each output a positive DC voltage VDC; and the cellrotation value specifies respective sets of switching signals for 1 toN−1 cells to each output the voltage VDC.
 12. The method of claim 11,wherein each cell rotation value specifies a number of active cells anda position of the active cells, wherein each active cell outputs thevoltage VDC.
 13. The method of claim 11, wherein generating, in responseto the voltage level signal and the cell rotation value, a set ofswitching signals, comprises: selecting, by the cell rotation value, aplurality of sets of switching signals, wherein each set of switchingsignals defines a specific number of up to N−1 cells to output thevoltage VDC; and selecting, based on the voltage level signal, one setof the plurality of sets of switching signals.